Combined Compression and Absorption Dressing/Bandage

ABSTRACT

A combined compression and absorption dressing/bandage, which includes a short stretch compression bandage and at least one absorptive wound dressing comprising at least one absorbent layer of a non-woven fabric of any one or more of cotton, viscose and polyester fibres, the absorbent layer having an operative inner face and an operative outer face, the at least one wound dressing being bonded to the short stretch compression bandage with its inner face towards the bandage and the outer face facing away from the bandage.

This invention relates to a combined compression and absorptiondressing/bandage. It relates also to a method of manufacturing acombined compression and absorption dressing/bandage, and to a method oftreating a wound.

BACKGROUND OF THE INVENTION

The inventor is aware of compression bandages used in combination withwound dressings to care for wounds by exerting compression on thewounds, whilst absorbing moisture from a wound.

SUMMARY OF THE INVENTION

Broadly according to one aspect of the invention, there is provided acombined compression and absorption dressing/bandage, which includes

a short stretch compression bandage; and

an absorptive wound dressing integral with at least a portion of thecompression bandage.

According to another aspect of the invention, there is provided acombined compression and absorption dressing/bandage, which includes

a short stretch compression bandage; and

at least one wound dressing comprising at least one absorbent layer of anon-woven fabric made up of cotton and viscose and polyester fibres, theabsorbent layer having an operative inner face and an operative outerface, the at least one wound dressing being bonded to the short stretchcompression bandage with its inner face towards the bandage and theouter face facing away from the bandage.

The combined compression and absorption dressing/bandage may include twoabsorbent outer layers of any one of non-woven viscose and cotton andpolyester fibres and a short stretch compression bandage inner layer.

The short stretch compression bandage may be of a polyester knit of 50g/m² to 150 g/m². In particular the short stretch compression bandagemay be of a polyester knit of about 70 g/m².

The short stretch compression bandage may be of a non-absorbent materialthat can stretch and that could adsorb liquids.

The inner layer may be of a polyester knit scrim sandwiched between thetwo outer layers.

The inner layer may have a yarn count of 30 threads/cm² to 50threads/cm². In particular, the inner layer may have a yarn count ofabout 40 threads/cm².

The inner layer may be of 100% polyester.

The two absorbent outer layers may each have a weight per unit area of70 g/m² to 200 g/m².

The absorbent outer layers may be in the form of needle punched fibrebatts or webs. The outer layers may comprise 60% to 80% viscose fibresby mass and 20% to 40% polyester fibres by mass. In particular, theouter layers may comprise about 70% viscose fibres by mass and about 30%polyester fibres by mass.

The fibre in the outer layers may have a fibre titre of 1.0 to 5 denier.The outer layers may have been subjected to a thermal treatment processto provide the outer layers with a substantially smooth outer surface.

The absorbent outer layers and the short stretch inner layer may bebonded together by means of a needle punching process with a needlepunching density of between 200 punches/cm² to 700 punches/cm².

The outer layers and the short stretch inner layer may be bondedtogether by means of a needle punching process with a needle punchingdensity of about 430 punches/cm².

The combined compression and absorption dressing/bandage may have athickness of between 1.5 mm and 3 mm. In particular, the compressionbandage may have a thickness of about 2 mm.

The combined compression and absorption dressing/bandage may have aweight per unit area of between 200 g/m² to 500 g/m². In particular, thecompression dressing/bandage may have a weight per unit area of about270 g/m².

The combined compression and absorption dressing/bandage may have lengthof about 0.5 m to 4 m and a width of about 75 mm to 100 mm.

The wound-dressing portion of the compression dressing/bandage may havea length of between 0.5 m to 2 m and a width corresponding with thewidth of the compression dressing/bandage.

The wound-dressing portion of the compression dressing/bandage may havea length of about 1.3 m.

Advantageously, the compression dressing/bandage may be used with eitherone of its operatively outer faces towards or in contact with the wound.

Broadly according to another aspect of the invention, there is provideda method of manufacturing a short stretch compression/dressing, whichincludes

manufacturing at least one needle-punched fibre bat of viscose andpolyester by means of a needle loom, the at least one bat having anoperative inner and outer face;

sandwiching a layer of short stretch polyester knit onto the at leastone fibre batt with its operatively inner face towards a layer of shortstretch polyester knit by means of a needle-punching process to form alayered short stretch laminated pad.

More particularly there is provided a method of manufacturing a shortstretch compression/dressing, which includes

manufacturing at least two needle-punched fibre bats of any one ofviscose, cotton and polyester by means of a needle loom, each bat havingan operative inner and outer face;

sandwiching at least one layer of short stretch polyester knit betweenthe at least two fibre batts with their operatively inner faces inface-to-face relationship towards the at least one layer of shortstretch polyester knit by means of a needle-punching process to form alayered short stretch laminated pad.

The at least one short stretch inner layer may be sandwiched by beingbonded together by means of a needle punching process with a needlepunching density of between 200 punches/cm² to 700 punches/cm². Inparticular, the outer layers and the short stretch inner layer may bebonded together by means of a needle punching process with a needlepunching density of about 430 punches/cm².

The invention extends to a method of treating a wound, which methodincludes bandaging the wound by making use of a combined compression andabsorption dressing/bandage as describe above.

The invention is now described, by way of a non-limiting example, withreference to the accompanying diagrammatic drawings.

DRAWING(S)

In the drawings:

FIG. 1 shows, schematically, a three dimensional view of a compressiondressing/bandage in accordance with the invention; and

FIG. 2 shows, schematically, a flow-diagram of steps forming part of themethod of making a dressing/bandage in accordance with the invention.

EMBODIMENT OF THE INVENTION

With reference to FIG. 1 of the drawings, a dressing/bandage inaccordance with the invention is generally designated by referencenumeral 10. For clarity, the thickness of the wound dressing 10 isexaggerated in FIG. 2. The wound dressing 10 is in the form of arectangular laminate pad which comprises first and second absorbentlayers 12, 14 and an inner layer 16 sandwiched between and bonded to thefirst and second absorbent layers 12, 14. The three layers 12, 14, 16are bonded together by means of a needle-punching process as hereinafterdescribed in further detail.

Each of the first and second absorbent layers 12, 14 is of a non-wovenfabric comprising about 70% viscose fibres by volume and about 30%polyester fibres by volume. The viscose fibres and polyester fibres areporous fibres having a length of about 3 mm to 10 mm and a fineness of2-2.5 denier. Further, each of the first and second absorbent layers 12,14 have a weight per unit area of about 100 g/m².

The inner layer 16 is in the form of 100% polyester short stretch weftknit scrim with a yarn count of 40 and a weight of 70 g/m².

The wound dressing 10 thus has a total weight per unit area of about 270g/m², and has a total thickness of about 1.5 mm-2.5 mm.

In particular, each of the first and second absorbent layers 12, 14 isin the form of a fibre batt or mat. The first absorbent layer 12 has anoperatively outer face 18 and an operatively inner face 20, and thesecond absorbent layer 14 has an operatively outer face 22 and anoperatively inner face 24. The first and second absorbent layers 12, 14are oriented such that their operatively inner faces 20, 24 are inface-to-face relationship, with the inner layer 16 thus being in contactwith the operatively inner faces 20, 24 of the first and secondabsorbent layers 12, 14. The three layers 12, 14, 16 together form athree-layered laminate pad or body.

As mentioned above, the first and second absorbent layers 12, 14 and theinner layer 16 are bonded together by means of a needle-punchingprocess, the needle punching density of the needle-punching processeffecting such bonding together of the layers 12, 14, 16 being about300-500 punches/cm². Further, the operatively outer layers 18, 22 of thefirst and second absorbent layers 12, 14 have been subjected to heattreatment, such that the wound dressing 10 is provided withsubstantially smooth and non-adherent outer faces, as will become moreapparent hereinafter when manufacturing of the wound dressing 10 isdescribed in more detail.

Importantly, the inner layer 16 is of a short stretch compressionbandage. The bandage can stretch in the direction of arrows 26 but notin the direction of arrow 28.

The compression dressing/bandage 16 can be supplied in lengths of 2 m to4 m and widths of 75 mm to 100 mm. The dimensions of the outer layers12, 14 are matched to the width of the bandage 16. The outer layers 12,14 run along the first 1.3 m of the dressing/bandage, where after alength of about 1.5 m to 2 m defines a normal stretch bandage.

FIG. 2 shows a flow diagram of steps employed in a method of making acompression dressing/bandage in accordance with the invention. In thisfigure, block 30 represents a blending process during which the 70%viscose fibres and 30% polyester fibres from which each of the absorbentlayers 12, 14 are manufactured, are blended. The blended fibres are thenmoved along a notional flow line 32 to a size-reduction processrepresented by block 34, during which size-reduction process the size ofblended fibre tufts are reduced. After the size reduction, the fibretufts are moved along a notional flow line 36 to a carding process,represented by block 38, during which carding process the fibres arecombed and disentangled, to arrange them in to a fibrous web having moreor less parallel fibres. After carding, the fibrous web is moved along anotional flow line 40 to a cross-lapping process, represented by block42. During the cross-lapping process, the fibrous web is build up, bylayering, to the desired finished non-woven weight. After cross-lapping,the fibrous web is moved along a notional flow line 44 to a needleloomwhere needle-punching takes place, to bond the fibres of the webtogether.

In this example, the fibrous web from which each of the absorbent layers12, 14 is formed undergoes four needle-punching runs, the variousneedle-punching runs being notionally represented by blocks 46, 50, 54and 58. Thus, the fibrous web passes through four needle boards. In thisexample, the needleloom employed to effect the needle-punching is afelting loom having four needle boards, so that the fibrous web is fedthrough the needleloom once only. Flow lines 48, 52 and 56 notionallyrepresent movement of the fibrous web respectively from theneedle-punching run 46 to the needle-punching run 50, from theneedle-punching run 50 to the needle-punching run 54, and from theneedle-punching run 54 to the needle-punching run 58.

Each of the needle boards of the needle loom is 0.25 m wide and 1 mlong, and has 4,000 needles mounted thereon. Thus, each needle board has16,000 needles/linear meter. Each of the needles has a diameter of 0.58mm, has a taper- or conical point and has 9 barbs. The fibrous web isfed through the needleloom at a feed rate of 3 m/minute, and thepunching frequency of each needle board is 800-1,000 punches/minute. Apunching density of between 300 and 500 punches/cm², depending on thepunching frequency, is thus obtained during each of the needle-punchingruns 46, 50, 54, 58. The fibrous web exposed to the needle-punching runs46, 50, 54, 58 thus yields a fibrous batt or mat which has been exposedto a total needle-punching density of between about 1,200 and 2000punches/cm².

During the first needle-punching run 46, the depth to which the needlespenetrate the fibrous web is about 5.4 mm, during the secondneedle-punching run 50 the depth of needle penetration is about 4.6 mm,during the third needle-punching run 54 the depth of needle penetrationis about 4.3 mm, and during the fourth and final needle-punching run 58the depth of needle penetration is about 3.2 mm.As mentioned above, once the fibrous web has been exposed to theaforedescribed needle-punching process, a fibrous batt or mat is formed.Said fibrous batt is then, if required, moved along a notional flow line60 to a chemical treatment process, represented by block 62, where thefibrous batt can be chemically treated. After said chemical treatment ofthe batt, one major face of the fibrous batt, which face is intended toform one of the operatively outer faces 18, 22 of the first and secondabsorbent layers 12, 14, is then exposed to a heat treatment process toprovide said outer face of the fibrous mat with a smooth, relativelynon-fluffed and non-adherent surface. Movement of the fibrous web fromthe chemical treatment process 62 to the heat treatment process isindicated by notional flow line 64, the heat treatment process beingrepresented by block 66. If chemical treatment of the fibrous batt isnot required, as is the case with the present example, it is moveddirectly from the needle-punching run 58 to the heat treatment process66. Subsequent to the aforedescribed heat treatment, the fibrous batt isthen moved along a notional flow line 68 to a winding and cuttingprocess, represented by block 70, where the batt is cut into therequired width and is wound onto a roller.Referring back to the flow diagram of FIG. 2, a notional flow line 72represents movement of two rolls of manufactured fibrous batt to alayering process, represented by block 74, where the short stretchbandage 16 is sandwiched between the first and second absorbent layers12, 14, each of which is in the form of the aforedescribed fibrous batt.In particular, the fibrous batts or absorbent layers 12, 14 are orientedsuch that their smoothened faces or surfaces, i.e. those faces orsurfaces which underwent heat treatment, face operatively outwardly.After sandwiching of the three layers 12, 14, 16, the layers are movedalong a notional flow line 76 to a needleloom which effects a bondingneedle-punching process or run, represented by block 78. The needleloomused for the bonding needle-punching process or run 78 is a loom havinga single needle board. The three layers are thus bonded together bymeans of the needle-punching run represented by block 78. During thisbonding needle-punching run 78, the feed rate, the type of and number ofneedles mounted on the needle board and the dimensions of the needleboard used is the same as that used during the needle-punching runs 46,50, 54, 58. During the bonding needle-punching run 78, the punchingfrequency of the needle board is such that a bonding punching density ofabout 300-350 punches/cm² is obtained. After the bonding needle-punchingrun 78, a sheet, which is in the form of a three-layered laminate pad,is thus yielded. The laminate pad or sheet is then moved along anotional flow line 80 to a cutting process, indicated by block 82, whereit is cut to yield the required size wound dressings 10. After the wounddressings 10 have been cut to the required size, they are moved along anotional flow line 84 to a packing station 86, where they are packaged,typically separately packaged into airtight packages. The packaged wounddressings are then moved along a notional flow line to a sterilizationprocess, represented by a block 90, where the packaged wound dressingsare sterilized in conventional fashion.

Naturally, the aforedescribed steps for making a wound dressing inaccordance with the invention need not all be executed on the sameproduction line. In fact, all the steps need not even be executed at thesame location or manufacturing plant.

Although the method, as far as manufacturing of the first and secondabsorbent layers 12, 14 are concerned, is hereinbefore described withreference to a needleloom which includes four needle boards, it is to beappreciated that a needle loom having a single needle board can alsoadvantageously be applied, in which case the fibrous web will be fedfour times through the needle loom.

By employing the method and raw materials as hereinbefore described, acompression dressing/bandage having a thickness of about 1.5 mm-2.5 mmis obtained.

The invention as described and illustrated provides a compressiondressing/bandage which can be used to dress a wide spectrum of wounds tolimbs and combines the effects of a wound dressing and a compressionbandage used in combination. The absorbent layers, being stretchable inunison with the short stretch bandage provides a comfortable fit andpermit long term treatment of wounds to limbs.

The porous viscose fibres have high moisture absorbing properties andare air-permeable. In turn, polyester fibres are relatively tough andstrong and have high abrasion resistance. In addition, polyester fibreshave the ability after heat treatment, to retain a smoothened orflattened profile. Because of the combination of viscose and polyesterfibres of the absorbent layers 12, 14 of the present compressiondressing/bandage, each of the outer layers 12, 14, whilst beingair-permeable, has exceptional moisture absorbing properties, thusyielding a relatively tough and strong compression dressing/bandage withhigh moisture absorbing properties. Further, because of the softness ofporous viscose fibres, the wound dressing 10 is relatively soft and thusresists discomfort to a patient whose wound is dressed by a wounddressing in accordance with the invention.

The wound dressing in accordance with the invention, by virtue of itsparticular construction and the way in which it is manufactured, isknown not only to absorb exudate from wounds, but also, because ofcapillary action stemming from the construction of the dressing, todirect absorbed exudates and bacteria away from a wound. Further, thewound dressing in accordance with the invention, because of saidcapillary action, has the ability to “kick-start” wounds that areclassified as unresponsive or dead wounds, i.e. wounds which do notexude moist or liquids. Furthermore, the wound dressing has the abilityto retain absorbed exudate, such that absorbed moist does not leak ordrip there from. The particular invention described herein has the addedadvantage of compression treatment related to improved blood and lymphcirculation.

Furthermore, because both the outer surfaces of the compressiondressing/bandage 10 are smoothened by the aforedescribed heat treatmentprocess, the dressing is non-directional, i.e. it can be used witheither of its faces in contact with a wound. Because the outer surfacesof the wound dressing are relatively non-adherent, the dressing inaccordance with the invention can comfortably be used with ointmentemployed in treatment of wounds.

The invention as described and illustrated thus provides a compressiondressing/bandage which not only has good absorption qualities, but alsoserves to improve blood and lymph circulation in the region of thewound. This is of particular importance where wounds are related toassociated circulatory conditions such as lymphodemia and other woundssuch as ulcers, burn wounds and.

What is claimed is: 1.-25. (canceled)
 26. A method of manufacturing ashort stretch combined compression and absorption dressing/bandage,which includes manufacturing at least two needle-punched fibre batts ofany one of viscose and cotton and polyester by means of a needle loom,each batt having an operative inner and outer face; sandwiching at leastone layer of short stretch polyester knit between the at least two fibrebatts with the operative inner face of the first fibre batt in directcontact with a first surface of the short stretch polyester knit and theoperative inner surface of the second fibre batt in direct contact witha second surface of the short stretch polyester knit; and bonding thelayers together by means of a needle-punching process to form a layeredshort stretch laminated pad.
 27. A method as claimed in claim 26, inwhich the at least one short stretch inner layer is sandwiched by beingbonded together by means of a needle punching process with a needlepunching density of between 200 punches/cm² to 700 punches/cm². 28.(canceled)
 29. A method of treating a wound, comprising: bandaging awound with a combined compression and absorption dressing/bandage,wherein the combined compression and absorption dressing/bandageincludes an inner layer sandwiched between a first outer layer and asecond outer layer; and wherein: the inner layer is a short stretchcompression bandage comprising a knit scrim; the first outer layercomprises a first absorptive wound dressing that is in direct contactwith a first surface of the inner layer, the first absorptive wounddressing comprising at least one first absorbent layer having a firstoperative inner surface and a first operative outer surface; the secondouter layer comprises a second absorptive wound dressing that is directcontact with a second surface of the inner layer, the second absorptivewound dressing comprising at least one second absorbent layer having asecond operative inner surface and a second operative outer surface; thefirst and second absorbent layers each comprise a non-woven fabric ofany one or more of cotton, viscose and polyester fibres; the firstoperative inner surface is in direct contact with the first surface ofthe inner layer; the second operative inner surface is in direct contactwith the second surface of the inner layer; and the first and secondouter surfaces face away from the inner layer. 30-33. (canceled)
 34. Amethod of treating a wound, comprising: bandaging a wound with acombined compression and absorption dressing/bandage, wherein: thecombined compression and absorption dressing/bandage includes a layeredshort stretch laminate pad that includes include at least one layer of ashort stretch polyester knit sandwiched between at least twoneedle-punched fibre batts; the short stretch polyester knit has a firstsurface and a second surface each of the needle-punched fibre batts havean operative inner and outer face and include any one of viscose,cotton, and polyester; the operative inner face of the first fibre battis in direct contact with the first surface of the short stretchpolyester knit and the operative inner surface of the second fibre battis in direct contact with the second surface of the short stretchpolyester knit; and said at least one layer of short stretch polyesternit and said at least two needle-punched fibre bats are bonded to oneanother via needle punching.